Vehicle door hinge structure

ABSTRACT

A vehicle door hinge structure includes a first bracket, a second bracket, a hinge arm and a compressible check structure. The hinge arm has a first end that s attached to the first bracket for pivoting movement about a first pivot axis. The second bracket is attached to a second end of the hinge arm for pivoting movement about a second pivot axis. The compressible check structure is fixed in position to the first bracket. The compressible check structure is adjacent to and spaced apart from a stop surface of the first bracket. The compressible check structure extends upward away from a surface of the first bracket in an uncompressed state. However, a movement limiting surface of the hinge arm contacts and compresses the compressible check structure during a portion of movement of the hinge arm.

FIELD OF THE INVENTION

The present invention generally relates to a vehicle door hinge structure. More specifically, the present invention relates to a check structure that retains a vehicle door in a fully open position.

BACKGROUND INFORMATION

A vehicle door can include a check structure that assists in retaining the door in one or more open positions after the door is moved from a closed position to an open position. Typically, the check structure includes a movement restricting mechanism that applies a force on the door to keep the door in one or more predetermined positions when opened. However, such check structures are not usually effective in all circumstances, such as when the vehicle is parked on a hill where the force of gravity can sometimes be sufficient to overcome the force of the check structure, thereby urging the door back to the closed position.

SUMMARY

One object of the disclosure is to provide a vehicle door with a check structure that retains the vehicle door in an open position with sufficient force such that the vehicle door can only be moved out of the open position by a predetermined level of force, such as force applied by a vehicle operator to the vehicle door.

In view of the state of the known technology, one aspect of the present disclosure is to provide a vehicle door hinge structure with a first bracket, a hinge arm, a second bracket and a compressible check structure. The first bracket has a first surface that extends in a first direction and a stop surface extends in a second direction transverse to the first direction. The hinge arm has a first end, a second end and a body portion extending from the first end to the second end. The first end is attached to the first bracket for pivoting movement about a first pivot axis that extends through the first surface of the first bracket such that the hinge arm pivots relative to the first bracket from a first position to a second position. The body portion of the hinge arm has a movement limiting surface that is spaced apart from the first surface by a first predetermined distance. The second bracket is attached to the second end of the hinge arm for pivoting movement about a second pivot axis that extends through the second bracket and the second end of the hinge arm. The second bracket pivots relative to the second end of the hinge arm. The compressible check structure is fixed in position along a portion of the first surface of the first bracket. The compressible check structure is adjacent to and spaced apart from the stop surface of the first bracket. The compressible check structure extends away from the first surface in an uncompressed state by a second predetermined distance that is greater than the first predetermined distance. The movement limiting surface the hinge arm contacts and compresses the compressible check structure during a portion of movement of the hinge arm between the first position and the second position.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a side view of a vehicle showing a door in a closed position, the door being supported by a hinge structure that includes a check structure in accordance with a first embodiment;

FIG. 2 is another side view of the vehicle showing the door in an intermediate open position in accordance with the first embodiment;

FIG. 3 is another side view of the vehicle similar to FIG. 2 showing the door in a fully open position exposing the hinge structure in accordance with the first embodiment;

FIG. 4 is a cross-sectional view of a portion the vehicle taken along the line 4-4 in FIG. 3, showing the hinge structure attached to the vehicle and to the door in accordance with the first embodiment;

FIG. 5 is perspective view of the hinge structure removed from the vehicle showing a body bracket, a first hinge arm, a second hinge arm, a door bracket and the check structure in accordance with the first embodiment;

FIG. 6 is a top view of the hinge structure with the body bracket, the first and second hinge arms and the door bracket shown in a closed position corresponding to the position of the door as shown in FIG. 1, in accordance with the first embodiment;

FIG. 7 is another top view of the hinge structure with the body bracket, the first and second hinge arms and the door bracket shown in an intermediate position, in accordance with the first embodiment;

FIG. 8 is yet another top view of the hinge structure with the body bracket, the first and second hinge arms and the door bracket shown in the intermediate position corresponding to the position of the door as shown in FIG. 2, in accordance with the first embodiment;

FIG. 9 is still another top view of the hinge structure with the body bracket, the first and second hinge arms and the door bracket shown in the fully open position corresponding to the position of the door as shown in FIG. 3, in accordance with the first embodiment;

FIG. 10 is a side view of the hinge structure shown in the closed position corresponding to the depiction in FIG. 6 in accordance with the first embodiment;

FIG. 11 is a cross-sectional view of a portion of the hinge structure taken along the line 11-11 in FIG. 10, showing a pivot axis about which the second hinge arm pivots relative to the body bracket and a pivot axis about which the door bracket pivots relative to the second hinge arm in accordance with the first embodiment;

FIG. 12 is another cross-sectional view of a portion of the hinge structure taken along the line 12-12 in FIG. 10, showing a pivot axis about which the first hinge arm pivots relative to the body bracket and a pivot axis about which the door bracket pivots relative to the first hinge arm in accordance with the first embodiment;

FIG. 13 is another cross-sectional view of the hinge structure showing a portion of the hinge structure depicted in FIG. 12 showing details of the check structure including a clip member and a bracket pin in accordance with the first embodiment;

FIG. 14 is a perspective view of a portion of the first hinge arm showing a clip aperture dimensioned to receive a portion of the clip member in accordance with the first embodiment;

FIG. 15 is a perspective view of the clip member shown removed from the hinge structure in accordance with the first embodiment;

FIG. 16 is a top view of the clip member shown removed from the hinge structure in accordance with the first embodiment;

FIG. 17 is a side view of the clip member shown removed from the hinge structure in accordance with the first embodiment;

FIG. 18 is an enlarged view of a portion of the hinge structure showing the first and second hinge arms and the door bracket in the intermediate position corresponding to the position of the hinge structure in FIG. 8 (corresponding to the depiction of the door in FIG. 2) with the clip member of the check structure snap-fitted to the bracket pin, in accordance with the first embodiment;

FIG. 19 is another enlarged view of a portion of the hinge structure showing the first and second hinge arms and the door bracket in the fully open position corresponding to the position of the hinge structure in FIG. 8 (corresponding to the depiction of the door in FIG. 3) with the clip member of the check structure spaced apart from the bracket pin, in accordance with the first embodiment;

FIG. 20 is a perspective view of a hinge structure having a body bracket, a hinge arm with a door bracket rigidly fixed thereto and a check structure that includes a clip member fixed to the hinge arm and a bracket pin fixed to the body bracket in accordance with a second embodiment;

FIG. 21 is a cross-sectional view of the hinge structure depicted in FIG. 20 showing the clip member of the check structure fixed to the hinge arm and the bracket pin fixed to the body bracket in accordance with the second embodiment;

FIG. 22 is a perspective view of a hinge structure having a body bracket, a first hinge arm, a second hinge arm, a door bracket and a check structure in accordance with the third embodiment;

FIG. 23 is a perspective view of a portion of the hinge structure showing a compressible member of the check structure installed to the body bracket in accordance with the third embodiment;

FIG. 24 is another perspective view of the portion of the hinge structure showing the compressible member of the check structure installed to the body bracket in accordance with the third embodiment;

FIG. 25 is a perspective view of the compressible member of the check structure shown removed from the hinge structure in accordance with the third embodiment;

FIG. 26 is a first side view of the compressible member of the check structure shown removed from the hinge structure in accordance with the third embodiment;

FIG. 27 is a second side view of the compressible member of the check structure shown removed from the hinge structure in accordance with the third embodiment;

FIG. 28 is a side view of a portion of the hinge structure showing one of the hinge arms in a location corresponding to the intermediate position (FIG. 2) with the hinge arm being spaced apart from the compressible member of the check structure in accordance with the third embodiment;

FIG. 29 is another side view of the portion of the hinge structure depicted in FIG. 28 showing the hinge arm in a location between the intermediate position (FIG. 2) and the fully open position (FIG. 3) with the hinge arm compressing the compressible member of the check structure in accordance with the third embodiment;

FIG. 30 is yet another side view of the portion of the hinge structure depicted in FIGS. 28 and 29 showing the hinge arm in a location between the compressible member and a surface of a support portion of the body bracket, the position of the hinge arm corresponding to the fully open position (FIG. 3) with the hinge arm being retained in the fully open position by the compressible member of the check structure in accordance with the third embodiment;

FIG. 31 is a side view of a portion of a hinge structure identical to that depicted in FIGS. 22-30 except that a second compressible member has been added showing the hinge arm in a location corresponding to a first open position with the hinge arm being located on a first side of the second compressible member and spaced apart from the compressible member of the check structure in accordance with a fourth embodiment;

FIG. 32 is another side view of the portion of the hinge structure depicted in FIG. 31 showing the hinge arm in a location between the first open position and the fully open position between the compressible member and the second compressible member in accordance with the fourth embodiment;

FIG. 33 is yet another side view of the portion of the hinge structure depicted in FIGS. 31 and 32 showing the hinge arm in a location between the compressible member and the surface of a support portion of the body bracket, the position of the hinge arm corresponding to the fully open position (FIG. 3) with the hinge arm being retained in the fully open position by the compressible member of the check structure in accordance with the fourth embodiment;

FIG. 34 is a side view of a hinge structure similar to that depicted in FIG. 10, having a body bracket, a first hinge arm, a second hinge arm, a door bracket and a check structure, the body bracket, the first and second hinge arms and the door bracket being similar to the first embodiment, with the check structure having a compressible member that is installed to the door bracket in accordance with a fifth embodiment;

FIG. 35 is a perspective view of a hinge structure similar to that depicted in FIG. 20, having a body bracket, a hinge arm with a door bracket rigidly fixed thereto and a check structure that includes a compressible member installed to the body bracket in accordance with a sixth embodiment;

FIG. 36 is a perspective view of a hinge structure similar to that depicted in FIGS. 20 and 35, having a body bracket, a hinge arm with a door bracket rigidly fixed thereto and a hydraulic check structure installed to the body bracket in accordance with a seventh embodiment;

FIG. 37 is a perspective view of a portion of the hinge structure depicted in FIG. 36, showing the hydraulic check structure in cross-section in accordance with a seventh embodiment;

FIG. 38 is an exploded perspective view of a portion of the hinge structure showing the various elements of the hydraulic check structure including a casing and a shaft with a fluid resistance paddle in accordance with the seventh embodiment;

FIG. 39 is a perspective view of the hydraulic check structure showing details of the casing and the shaft in accordance with the seventh embodiment;

FIG. 40 is a schematic cross-sectional top view of the internal components of the hydraulic check structure showing the shaft and the fluid resistance paddle is a position corresponding to a fully open position (FIG. 3) in accordance with the seventh embodiment;

FIG. 41 is another schematic cross-sectional top view of the internal components of the hydraulic check structure similar to FIG. 40 showing the shaft and the fluid resistance paddle is a position corresponding to an intermediate position (FIG. 2) in accordance with the seventh embodiment;

FIG. 42 is yet another schematic cross-sectional top view of the internal components of the hydraulic check structure with the shaft and the fluid resistance paddle is a position corresponding to a closed position (FIG. 1) in accordance with the seventh embodiment;

FIG. 43 is a perspective view of a hinge structure having a body bracket and a door bracket pivotally connected to one another with the hydraulic check structure attached to the body bracket in accordance with an eighth embodiment; and

FIG. 44 is a perspective view of a hinge structure having a body bracket and a door bracket pivotally connected to one another with the hydraulic check structure attached to the body bracket in accordance with a ninth embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to FIG. 1-3, a vehicle 10 that includes a door 12 and a door opening 13. The door 12 is configured to open, exposing the door opening 13, and close, covering the door opening 13. The door 12 is further configured such that, in a closed position, an outer surface 14 of the door 12 conforms to and aligns with an outer surface 16 of the vehicle 10, as shown in FIG. 1. In a fully open position, the outer surface 14 of the door 12 faces and overlays a portion of the outer surface 16 of the vehicle 10, as shown in FIG. 3. FIG. 2 shows the door 12 in an intermediate position and FIG. 3 shows the door 12 in a fully open position, with the outer surface 14 of the door 12 overlaying and covering a portion of the outer surface 16 of the vehicle 10.

The vehicle 10 is depicted as a pickup truck having a plurality of doors. However, it should be understood from the drawings and the description below, that the vehicle 10 can be any of a variety of vehicles, such as a van, a sports utility vehicle, a commercial van or a passenger vehicle such as a sedan or a coupe. Further the door 12 can be a front door, rear door, back door or any hinged door of such vehicles and is not limited to the back door depicted in FIG. 1-3. More specifically, the hinge structures described herein below, can be used on any vehicle closure panel that pivots about an axis between a closed position and an open position.

As shown in FIGS. 3 and 4, the door 12 is supported to the vehicle 10 for pivoting movement by hinge structures 20. As shown in FIG. 3, there can be two hinge structures 20 supporting the door 12. FIG. 4 is a top view of one of the hinge structures 20, described in greater detail below. The hinge structure 20 is configured allow the door 12 to move along an arcuate path between the fully open position and the closed position with an angular movement range of approximately 170 degrees. The hinge structure 20 includes a check structure 22 that restricts movement of the door 12 when the door 12 is moved to the fully open position, as is described in greater detail below. In the depicted embodiment, only one of the hinge structures 20 includes the check structure 22 in a manner described further below. However, it should be understood from the drawings and the description herein that both hinge structures 20 can be equipped with the check structure 22.

Before describing the check structure 22, a description of one of the hinge structures 20 is provided with specific reference to FIGS. 3-11. Since the hinge structures 20 are basically the same, description of only one of the hinge structures 20 is included for the sake of brevity.

As shown in FIG. 5, the hinge structure 20 includes a body bracket 30, a door bracket 32, a first hinge arm 34, a second hinge arm 36, an optional primary check structure 38 and the check structure 22. As shown in FIGS. 5 and 6, the first hinge arm 34 defines a lengthwise direction D_(L), a widthwise direction D_(W) and a height-wise direction D_(H) (FIG. 5 only).

The body bracket 30 includes lower attachment flange 30 a, lower plate 30 b, a mid-plate 30 c, a top plate 30 d and an upper flange 30 e. The lower attachment flange 30 a and the upper attachment flange 30 e are configured to receive mechanical fasteners for the purpose of securely attaching the body bracket 30 to the vehicle 10. Alternatively, the body bracket 30 can be welded to the vehicle 10. In FIGS. 3 and 4, the body bracket 30 is shown fixedly attached to a pillar structure of the vehicle 10 in a conventional manner. When installed to the vehicle 10, the lower attachment flange 30 a and the upper attachment flange 30 e are upright and extend in a vertical direction.

The lower plate 30 b, the mid-plate 30 c and the top plate 30 d are all horizontally oriented and are preferably parallel to one another. The lower plate 30 b, the mid-plate 30 c and the top plate 30 d are all rigidly connected to one another via support portions 30 f and 30 g of the body bracket 30, as shown in FIG. 5.

The lower attachment flange 30 a, the lower plate 30 b, the mid-plate 30 c, the top plate 30 d, the upper flange 30 e and support portions 30 f and 30 g are preferably made of a metallic material such as hardened steel but can alternatively be made of other metal materials. Combinations of the lower attachment flange 30 a, the lower plate 30 b, the mid-plate 30 c, the top plate 30 d, the upper flange 30 e and support portions 30 f and 30 g can be stamped from a single sheet of metal with remaining portions being welded in place as shown in FIG. 5.

The door bracket 32 includes a main portion 32 a, a lower plate 32 b, a mid-plate 32 c and an upper plate 32 d. The main portion 32 a is a generally flat portion of the door bracket 32 and is configured to receive mechanical fasteners for the purpose of securely attaching the door bracket 32 to the door 12. Alternatively, the door bracket 32 can be welded to the door 12. In FIGS. 3 and 4, the door bracket 32 is shown fixedly attached to the door 12 of the vehicle 10 in a conventional manner. When installed to door 12 of the vehicle 10, the main portion 32 a is upright and extends in a vertical direction.

The lower plate 32 b, the mid-plate 32 c and the upper plate 32 d are all horizontally extending portions of the door bracket 32 with the door bracket 32 installed to the door 12 and the door 12 installed to the vehicle 10. The lower plate 32 b, the mid-plate 32 c and the upper plate 32 d are fixedly attached to the main portion 32 a. More specifically, the lower plate 32 b, the mid-plate 32 c and the upper plate 32 d can be unitarily formed with the main portion 32 a or can be welded thereto. The lower plate 32 b, the mid-plate 32 c and the upper plate 32 d are spaced apart from one another.

The door bracket 32 is preferably made of a metallic material such as hardened steel but can alternatively be made of other metal materials.

The first hinge arm 34 has a curved or gooseneck shape and is also referred to herein below as a gooseneck member. The first hinge arm 34 is shaped such that with respective pivoting ranges relative to the body bracket 30 and the door bracket 32, the first hinge arm 34 provides the door 12 with freedom to move from the closed position (FIG. 1) to the fully open position with a pivoting range of approximately 170 degrees, as is described in greater detail below.

As shown in FIG. 12, the first hinge arm 34 has a first end 34 a, a main section 34 b and a second end 34 c. The first end 34 a is attached to the body bracket 30 for pivoting movement about a first pivot axis A₁. The first pivot axis A₁ extends through the body bracket 30 such that the first hinge arm 34 pivots relative to the body bracket 30 with a pivoting range represented by an angle α₁. The first pivot axis A₁ is defined by a pivot pin P₁. The pivot pin P₁ extends through apertures formed in the mid-plate 30 c and the top plate 30 d. Specifically, the pivot pin P₁ extends through the mid-plate 30 c and the top plate 30 d and is restrained against movement in an axial direction by, for example, fasteners or C-clips (not shown) in a conventional manner. As shown in FIG. 12, the pivoting range represented by the angle α₁ is approximately 100 degrees.

The second end 34 c of the first hinge arm 34 is attached to the door bracket 32 for pivoting movement about a second pivot axis A₂. The second pivot axis A₂ extends through the door bracket 32 such that the first hinge arm 34 pivots relative to the door bracket 32 with a pivoting range represented by an angle α₂. The second pivot axis A₂ is defined by a pivot pin P₂. The pivot pin P₂ extends through apertures formed in the mid-plate 32 c and the upper plate 32 d. Specifically, the pivot pin P₁ extends through the mid-plate 30 c and the top plate 32 d and is restrained against movement in an axial direction by, for example, fasteners or C-clips (not shown) in a conventional manner. As shown in FIG. 12, the pivoting range represented by the angle α₂ is approximately 70 degrees. The actual pivoting ranges represented by the angles α₁ and α₂ can vary from vehicle to vehicle and hinge structure to hinge structure. However, in the depicted embodiment of the hinge structure 20, the angles α₁ and α₂ when combined provide the hinge structure 20 and the door 12 with an overall pivoting range of approximately 170 degrees from the closed position of the door 12 to the open position of the door 12.

As shown in FIG. 13, the main section 34 b of the first hinge arm 34 has a first side 34 d and a second side 34 e. In the first embodiment, the main section 34 b includes a clip aperture 34 f that extends from the first side 34 d to the second side 34 e. Specifically, the clip aperture 34 f extends in the widthwise direction D_(W) of the first hinge arm 34. The clip aperture 34 f is located proximate the second end 34 c of the first hinge arm 34. As shown in FIG. 14, the clip aperture 34 f has a first height H₁ in a vertical direction (relative to the vehicle 10). The main section 34 b of the first hinge arm 34 has an overall thickness T₁ in the vertical direction that is several times the size of the first height H₁. Specifically, the overall thickness T₁ is more than twice the size of the first height H₁. Further, the clip aperture 34 f is centrally located relative to the overall thickness T₁ of the first hinge arm 34. Above the clip aperture 34 f, the adjacent portion of the main section 34 b of the first hinge arm 34 has a thickness T₂ and below the clip aperture 34 f, the adjacent portion of the main section 34 b of the first hinge arm 34 has a thickness T₃. In the depicted embodiment, the thickness T₂ is equal to the thickness 13. Further, in the depicted embodiment each of the thicknesses T₂ and T₃ is equal to or greater than the first height H₁ of the clip aperture 34 f. The clip aperture 34 f also has a width W₁, as shown in FIG. 14.

The second hinge arm 36 has a curved or gooseneck shape similar to the first hinge arm 34, and is also referred to herein below as a gooseneck member. The second hinge arm 36 is shaped such that with respective pivoting ranges relative to the body bracket 30 and the door bracket 32, the first hinge arm 34 and the second hinge arm 36 provide the door 12 with freedom to move from the closed position (FIG. 1) to the fully open position with a pivoting range of approximately 170 degrees, as is described in greater detail below.

As shown in FIG. 11, second hinge arm 36 has a first end 36 a, a main section 36 b and a second end 36 c. The first end 36 a is attached to the body bracket 30 for pivoting movement about a third pivot axis A₃. The third pivot axis A₃ extends through the body bracket 30 such that the second hinge arm 36 pivots relative to the body bracket 30 with a pivoting range represented by an angle α₃. The third pivot axis A₃ is defined by a pivot pin P₃. The pivot pin P₃ extends through apertures formed in the lower plate 30 b and the mid-plate 30 c. Specifically, the pivot pin P₃ extends through the lower plate 30 b and the mid-plate 30 c and is restrained against movement in an axial direction by, for example, fasteners or C-clips (not shown) in a conventional manner. As shown in FIG. 11, the pivoting range represented by the angle α₃ is approximately 100 degrees.

The second end 36 c of the second hinge arm 36 is attached to the door bracket 32 for pivoting movement about a fourth pivot axis A₄. The fourth pivot axis A₄ extends through the door bracket 32 such that the second hinge arm 36 pivots relative to the body bracket 30 with a pivoting range represented by an angle α₄. The fourth pivot axis A₄ is defined by a pivot pin P₄. The pivot pin P₄ extends through apertures formed in the lower plate 32 b and mid-plate 32 c. Specifically, the pivot pin P₄ extends through the lower plate 32 b and mid-plate 32 c and is restrained against movement in an axial direction by, for example, fasteners or C-clips (not shown) in a conventional manner. As shown in FIG. 11, the pivoting range represented by the angle α₄ is approximately 70 degrees. The actual pivoting ranges represented by the angles α₃ and α₄ can vary from vehicle to vehicle and hinge structure to hinge structure. However, in the depicted embodiment of the hinge structure 20, the angles α₃ and α₄ when combined provide the hinge structure 20 and the door 12 with an overall pivoting range of approximately 170 degrees from the closed position of the door 12 to the open position of the door 12.

As is shown in FIGS. 6-9, the first hinge arm 34 and the second hinge arm 36 have similar overall shapes and curvatures, with slight differences. Specifically, the first pivot axis A₁ and third pivot axis A₃ are spaced apart from one another and the second pivot axis A₂ and fourth pivot axis A₄ are spaced apart from one another. All four pivot axes A₁, A₂, A₃ and A₄ are parallel to one another. A first distance D₁ is defined between the first pivot axis A₁ and the third pivot axis A₃ and a second distance D₂ is defined between the second and fourth pivot axis A₂ and A₄. The first distance D₁ is greater than the second distance D₂.

The geometry of the first hinge arm 34 and the second hinge arm 36 and their respective pivot axes is such that with the hinge structure 20 in the orientation shown in FIG. 6 (corresponding to the door 12 being in the closed position in FIG. 1) the main portion 32 a of the door bracket 32 is close to or approximately perpendicular to the lower and upper attachment flanges 30 a and 30 e of the body bracket 30. As the door 12 is opened moving the door bracket 32 toward the position shown in FIG. 7 and then FIG. 8 (corresponding approximately to the intermediate position of the door 12 in FIG. 2), the main portion 32 a of the door bracket 32 become approximately parallel to the lower and upper attachment flanges 30 a and 30 e of the body bracket 30. Finally, as shown in FIG. 9 (corresponding to the door 12 being fully opened as shown in FIG. 3) the main portion 32 a of the door bracket 32 is again approximately perpendicular to the lower and upper attachment flanges 30 a and 30 e of the body bracket 30, but is rotated approximately 170 degrees from the orientation depicted in FIG. 6.

The optional primary check structure 38 is mechanism that permits the hinge structure 20 the door 12 to open and close. The optional primary check structure 38 is further configured and structured with a spring loaded mechanism that serves to provide resistance to movement of the door 12 with the door in at least one open position and optionally several open positions. The optional primary check structure 38 includes a shaft (not shown) that is attached to the pivot pin P₁ and a housing fixed to the body bracket 30. One example of the optional primary check structure 38 is disclosed in, for example, U.S. Pat. No. 7,103,938, issued Sep. 26, 2006 to Bruckner et al., and is incorporated herein by reference. The optional primary check structure 38 is not required with the hinge structure 20 and is purely optional.

The optional primary check structure 38 serves as one means for retaining the door 12 in at least one open position. However, when the door 12 is fully open, as is shown in FIG. 3, additional means for retaining the door 12 in the fully open position may be necessary under certain circumstances, such as parking on a hill, or in windy conditions where external forces may urge the door 12 into moving from the fully open position (FIG. 3) to the closed position (FIG. 1).

Consequently, the check structure 22 is provided on the hinge structure 20 in order to maintain the door 12 in the fully open position in any of a variety of circumstances. The check structure 22 is a structure that restricts movement of the hinge structure 20 and the door 12 when the door 12 is in the fully open position as shown in FIG. 3. When the door 12 is in the fully open position shown in FIG. 3, the hinge structure 20 is oriented as shown in FIG. 9. As is described in greater detail below, in order to move the door 12 to the fully open position, a vehicle operator must use a predetermined level of force in order to put the door 12 in the fully open position. Similarly, the vehicle operator must use approximately the same predetermined level of force in order to move the door 12 away from the fully open position (FIG. 3) to any other position of the door 12, such as the intermediate position of the door 12 shown in FIG. 2.

The check structure 22 is now described with specific reference to FIG. 13 thru 19. As shown in FIG. 13, the check structure 22 includes a clip member 40 and a bracket pin 42. As shown in FIGS. 15-17, the clip member 40 having a main body 44, a clip portion 46 located at a first end 44 a of the main body 44, and a retention portion 48 located at a second end 44 b of the main body 44. As shown in FIGS. 13, 18 and 19, clip member 40 is installed to the first hinge arm 34 by inserting the retention portion 48 completely through the clip aperture 34 f such that the main body 44 of the clip member 40 remains within the clip aperture 34 f and extends through the clip aperture 34 f. The clip portion 46 is then positioned on the first side 34 d of the hinge arm 34 and the retention portion 48 is positioned on the second side 34 e of the hinge arm 34.

The retention portion 48 of the clip member 40 includes a pair of first compressible flanges 48 a and a pair of second compressible flanges 48 b. The first and the second compressible flanges 48 a and 48 b extend from the second end 44 b of the main body 44 of the clip member 40 toward the first end 44 a of the main body 44. Respective distal ends of the first and the second compressible flanges 48 a and 48 b face the second side 34 e of the first hinge arm 34 with the main body 44 inserted into the clip aperture 34 f, thereby preventing the retention portion 48 from passing through the clip aperture 34 f from the second side 34 e of the first hinge arm 34 to the first side 34 d. The first and the second compressible flanges 48 a and 48 b have respective lengthwise extending surfaces that define an acute angle as relative to an adjacent one of the first and second side surfaces 44 e and 44 f of the main body 44 of the clip member 40.

The bracket pin 42 is fixedly attached to the door bracket 32 at a location spaced apart from the second pivot axis A₂ such that the clip portion 46 of the clip member 40 engages the bracket pin 42 when the door bracket 20 is in a position corresponding to the fully open position of the door 12. The bracket pin 42 is rigidly and fixedly attached to both the mid-plate 32 c and the upper plate 32 d of the door bracket 32. The main body 44 of the clip member 40 has a rectangular cross-sectional shape and the clip aperture 34 f of the first hinge arm 34 has a corresponding rectangular shape. Further, the main body 44 and the clip aperture 34 f are dimensioned to prevent rotation of the clip member 44 with the main body 44 inserted into the clip aperture 34 f.

As shown in FIGS. 15-17, the main body 44 of the clip member 40 has a top surface 44 c, a bottom surface 44 d, a first side surface 44 e and a second side surface 44 f. The top surface 44 c and the bottom surface 44 d are substantially parallel to one another. The first side surface 44 e and the second side surface 44 f are substantially parallel to one another and perpendicular to the top and the bottom surfaces 44 c and 44 d.

The clip portion 46 has a base 46 a, a first clip arm 46 b and a second clip arm 46 c. The base 46 a has a width W₃ (FIG. 16) that is wider than the width W₁ of the clip aperture 34 f. With the clip member 40 installed to the first hinge arm 34, the base 46 a is located adjacent the first side 34 d of the first hinge arm 34. The first clip arm 46 b and the second clip arm 46 c (a pair of clip arms) of the clip portion 46 extend away from opposite edges of the base 46a and extend away from the first hinge arm 34. However, the first clip arm 46 b and the second clip arm 46 c extend away from the base 46 a and the main body 44 of the clip member 40 in directions that are non-parallel relative to a lengthwise direction of the main body 44.

As shown in FIG. 16, the first clip arm 46 b and the second clip arm 46 c have arcuate shapes and curve in directions toward the second end 34 c of the first hinge arm 34. More specifically, the first clip arm 46 b, curves outward from the base 46 a and toward the second end 34 c of the first hinge arm 34. The second clip arm 46 c has a first portion 46 c ₁ that, like the first clip arm 46 b, curves outward from the base 46 a and toward the second end 34 c of the first hinge arm 34. However, an end portion 46 c ₂ of the second clip arm 46 c curves in a serpentine manner curving outward away from the base 46 a, the first clip arm 46 b and the first portion 46 c ₁. Thus, distal ends of the first clip arm 46 b and the second clip arm 46 c diverge, extending away from one another.

As is shown in FIGS. 16 and 18, at a point where the arcuate portions of the first clip arm 46 b and the second clip arm 46 c are closest to one another, a gap G₁ is defined with a first distance L₁ being defined at the gap G₁. Distal ends of the first clip arm 46 b and the second clip arm 46 c further define a gap G₂ with a second distance L₂ being defined therebetween. Further, at the intersection of the first clip arm 46 b and the second clip arm 46 c and the base 46 a, the first clip arm 46 b and the second clip arm 46 c are spaced apart from one another by a third distance L₃. The second distance L₂ is greater than the first and third distances L₁ and L₃. Further, the third distance L₃ is greater than the first distance L₁. As is shown in FIGS. 13, 18 and 19, the gaps G₁ and G₂ align with the bracket pin 42 as the hinge structure 20 moves the door 12 to the fully open position. Further, the distal ends of the first clip arm 46 b and the second clip arm 46 c face the bracket pin 42 as the hinge structure 20 moves the door 12 to the fully open position.

The bracket pin 42 has an outer surface that defines a diameter D₃. As shown in FIGS. 13, 18 and 19, the diameter D₃ is larger than the first distance L₁ but smaller than the second distance L₂. Further, the third distance L₃ and the diameter D₃ are dimensioned such that with the bracket pin 42 located against the base 46 a of the clip portion 46 between the first and second clip arms 46 b and 46 c, the first and second clip arms 46 b and 46 c snugly retain the bracket pin 42 therebetween, as shown in FIG. 19. The clip member 40 is made of either a metallic material or strong polymer materials such that the first and second clip arms 46 b and 46 c are resilient with some elasticity. Specifically, the first and second clip arms 46 b and 46 c elastically move away from one another when the bracket pin 42 is pushed therebetween. However, the first and second clip arms 46 b and 46 c have sufficient biasing force to retain the bracket pin 42 therebetween and hold the door 12 in the fully open position (FIG. 3).

Hence, when the door 12 is moved to the fully open position (FIG. 3) the door bracket 32 is rotated in an arcuate path bringing the first and second clip arms 46 b and 46 c into contact with the bracket pin 42. The vehicle operator moving the door 12 to the fully open position applies a predetermined amount of force to the door 12 thereby pushing the first and second clip arms 46 b and 46 c such that they elastically move away from each other due to contact with the bracket pin 42 and the bracket pin 42 is forced therebetween. In effect, the first and second clip arms 46 b and 46 c snap-fit around the bracket pin 42. Once completely in the fully open position (FIG. 3), the first and second clip arms 46 b and 46 c snugly retain the bracket pin 42 and hence retain the door 12 in the fully open position (FIG. 3). In order to move the door 12 out of the fully open position, the door 12 is pulled with a predetermined amount of force, thereby pulling the first and second clip arms 46 b and 46 c away from the bracket pin 42.

The check structure 22 is advantageous in that it prevents the door 12 from moving away from the fully open position by, for example, excessive amounts of wind urging the door 12 to move, or gravity, when the vehicle 10 is parked on a slope or hill where gravity might otherwise urge the door 12 to close. It should be understood from the drawings and the description herein that the clip member 40 of the check structure 22 can be made of any of a variety of materials and be re-dimensioned in order to exert sufficient force to the bracket pin 42 in order to retain the door 12 in the fully open position.

Second Embodiment

Referring now to FIGS. 20 and 21, a hinge structure 120 having the check structure 22 in accordance with a second embodiment will now be explained. In view of the similarity between the first and second embodiments, the parts of the second embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the second embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity.

In the second embodiment, the hinge structure 20 is replaced with the hinge structure 120. The hinge structure 120 is provided with the check structure 22 as described above with respect to the first embodiment.

The hinge structure 120 includes a body bracket 130 and a hinge arm 134. The body bracket 130 includes a pivot pin P₅ such that the hinge arm 134 pivots relative to the body bracket 130 about the pivot pin P₅. The hinge arm 134 is formed integrally with a door bracket portion 132 as a single, unitary, monolithic element. The body bracket 130 is configured to attach to the vehicle 10 and the door bracket portion 132 is configured to attach to the door 12 in a manner similar to the hinge structure 20 of the first embodiment. However, as discussed above, the hinge structure 20 of the first embodiment is configured to support the door 12 for pivoting movement along a 170 degree movement path. In the second embodiment, the hinge structure 120 is configured to support the door 12 for pivoting movement along a movement path that is less than 170 degrees, for example, 90 degrees.

The check structure 22 includes the clip member 40 and the bracket pin 42, as described above. However, in the second embodiment, the bracket pin 42 is fixed to the body bracket 130 and the clip member 40 is installed into a clip aperture formed in the hinge arm 134 adjacent to the body bracket 130. The function of the check structure 22 is identical to the usage in the first embodiment, except that a different hinge structure is provided with the check structure 22.

Third Embodiment

Referring now to FIGS. 22-30, a hinge structure 20′ having a compressible check structure 122 in accordance with a third embodiment will now be explained. In view of the similarity between the first and third embodiments, the parts of the third embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the third embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity.

The hinge structure 20′ of the third embodiment is identical to the hinge structure 20 of the first embodiment, except that the check structure 22 is removed and replaced with the compressible check structure 122. Specifically, both the clip member 40 and the bracket pin 42 are removed from the hinge structure 20 and replaced with the compressible check structure 122.

More specifically, the hinge structure 20′ includes the body bracket 30, the door bracket 32, the first hinge arm 34, the second hinge arm 36 and (optionally) the primary check structure 38, as described above with respect to the first embodiment, except that the check structure 22 is removed or omitted. Since the body bracket 30, the door bracket 32, the first hinge arm 34 and the second hinge arm 36 include all of the structures and features described in the first embodiment, description of these elements for the third embodiment is omitted for the sake of brevity.

The compressible check structure 122 basically includes a stop surface 30 h (see FIGS. 11, 12, 22 and 28-30) formed on the support portion 30 f of the body bracket 30, a movement limiting surface 36 i defined along an underside of the second hinge arm 36 and a compressible member 140. The compressible member 140 has a main body 144, a compressible portion 146 and a retention portion 148.

Further, in the third embodiment, the lower plate 30 b of the body bracket 30 includes an aperture 30 i, as shown in FIG. 23. The compressible member 140 is fixed to the lower plate 30 b by the installation of the main body 144 into the aperture 30 i. Once installed, the retention portion 148 is located on a lower surface of the lower plate 30 b of the body bracket 30 and the compressible portion 146 is located along an upper surface of the lower plate 30 b of the body bracket 30.

The main body 144 has a rectangular cross-section, and the aperture 30 i has a corresponding rectangular shape. Further, the main body 144 and the aperture 30 i are dimensioned to prevent rotation of the compressible member 140 with the main body 144 inserted into the aperture 30 i.

The compressible member 140, and in particular, the compressible portion 146 of the compressible member 140, is made of an elastic material such that contact between the compressible portion 146 and the movement limiting surface 36 i of the hinge arm 36 during movement of the hinge arm 36 generates friction therebetween.

The compressible portion 146 of the compressible member 140 is located on the body bracket 30 at a location that is adjacent to but spaced apart from the stop surface 30 h of the body bracket 30 j. Specifically, the compressible portion 146 is spaced apart from the stop surface 30 h by a distance D₄, as shown in FIG. 28. Further, the compressible portion 146 extends upward from the upper surface of the lower plate 30 b in an uncompressed state by a distance D₅, as is also shown in FIG. 28. In other words, the compressible portion 146 has a height in an uncompressed state that is equal to the distance D₅, as is also shown in FIG. 28.

As shown in FIGS. 28-30, when pivoting about the third axis A₃, the second hinge arm 36 moves in directions parallel to the lower plate 30 b. During the pivoting movement of the second hinge arm 36, the second hinge arm 36 is spaced apart from the lower plate 30 b of the body bracket 30 by a distance D₆, as shown in FIG. 28. The distance D₆ is less than the distance D₅. Consequently, when the second hinge arm 36 moves over the compressible portion 146 of the compressible member 140, the movement limiting surface 36 i contacts the compressible portion 146 compressing the compressible portion 146, as shown in FIG. 29, and described in greater detail below.

The retention portion 148 includes compressible flanges that are essentially the same as the first compressible flanges 48 a and the second compressible flanges 48 b described above with respect to the first embodiment. Since the dimensions, purpose and function of the compressible flanges of the retention portion 148 are basically the same as or identical to dimensions, purpose and function of the first compressible flanges 48 a and the second compressible flanges 48 b of the clip member 40 of the first embodiment, further description is omitted for the sake of brevity.

As shown in FIGS. 28-30, when the second hinge arm 36 (and hence the door 12) is moved from the intermediate position (FIG. 2) to the fully open position (FIG. 3), the movement limiting surface 36 i of the second hinge arm 36 contacts and compresses the compressible portion 146. As mentioned above and shown in FIG. 28, the movement limiting surface 36 i is spaced apart from the lower plate 30 b by the distance D₆, which is smaller than the height (the distance D₅) of the compressible portion 146. Consequently, as shown in FIG. 29, contact between the movement limiting surface 36 i and the compressible portion 146 compresses the compressible portion 146. This contact generates friction between the compressible member 140 and the second hinge arm 36, requiring a vehicle operator to apply additional force on the hinge structure 20′ (and the door 12) in order to move the second hinge arm 36 over the compressible portion 146. Therefore, once the second hinge arm 36 is moved to the position shown in FIG. 30, the compressible portion 146 decompresses to the height (distance D₅) and retains the second hinge arm 36 in the depicted position (corresponding to the fully open position of the door 12 in FIG. 3). The second hinge arm 36 and hence the door 12 is retained in the fully open position with the second hinge arm 36 in the position shown in FIG. 30 until the movement described above is reversed while sufficient force is applied to the door 12 and the hinge structure 20′ to overcome the friction forces generated by movement of the second hinge arm 36 back to the position shown in FIG. 28.

The second hinge arm 36 has a width that is equal to the distance D₇, as shown in FIG. 28. The distance D₇ is approximately equal to or slightly less than the distance D₄ between the stop surface 30 h and the compressible member 140. Therefore, when the second hinge arm 36 is positioned within the space or gap between the stop surface 30 h and the compressible member 140, the second hinge arm 36 and hence the hinge structure 20′ and the door 12 are snuggly retained in the fully open position (FIG. 3).

The compressible check structure 122 provides essentially the same function and benefits to the hinge structure 20′ as the check structure 22 provides to the hinge structure 20 of the first embodiment. For example, as shown in FIGS. 28-30, the compressible member 140 has ramped leading surface 140 a and ramped trailing surface 140 b. There is a gradual increase in resistance to movement as the second hinge arm 36 contacts the ramped leading surface 140 a a begins to compress the compressible member 140. Similarly, there is a gradual decrease of resistance to movement as the second hinge arm 36 moves along the ramping trailing surface 140 b. This gives the effect similar to more conventional check structures.

Fourth Embodiment

Referring now to FIGS. 31-33, the hinge structure 20′ of the third embodiment is modified to include a second compressible member 140′ in accordance with a fourth embodiment.

Basically, the hinge structure 20′ is exactly as described above with respect to the third embodiment, except that a second compressible member 140′ has been added to the second hinge arm 36, as shown in FIGS. 31-33. The second compressible member 140′ includes a main body 144′, a compressible portion 146′ and a retention portion 148′ that are identical to the main body 144, the compressible portion 146 and the retention portion 148 described above with respect to the third embodiment. However, the second compressible member 140′ is spaced apart from the compressible member 140 thereby providing a retention location that is separate and distinct from the fully open position of the door 12 represented in FIG. 33. Specifically, as shown in FIG. 32, the second hinge arm 36 can be retained in the retention location defined between the compressible member 140 and the second compressible member 140′.

Fifth Embodiment

Referring now to FIG. 34, a hinge structure 20″ in accordance with a fifth embodiment will now be explained. In view of the similarity between the second and fifth embodiments, the parts of the fifth embodiment that are identical to the parts of the second embodiment will be given the same reference numerals as the parts of the second embodiment. Moreover, the descriptions of the parts of the fifth embodiment that are identical to the parts of the second embodiment may be omitted for the sake of brevity. The parts of the fifth embodiment that differ from the parts of the second embodiment will be indicated with a double prime (″).

In the fifth embodiment, the hinge structure 20″ is identical to the hinge structure 20 of the first embodiment, except that the check structure 22 has been removed and a compression check structure 122″ has been added. Specifically, the compression check structure 122″ includes the compression member 140 as described above with respect the third embodiment. The compression member 140 has been installed to the door bracket 32 for compressive contact with the second hinge arm 36. Contact between the second hinge arm 36 and the compression member 140 provides essentially the same effects and function of the compressible check structure 122 of the third embodiment. Alternatively, a compression member 140 a′ (shown in phantom in FIG. 34) can be installed to the door bracket 32 for compressive contact with the first hinge arm 34. Further, the compression member 140 a′ can be installed to the door bracket 32 for compressive contact with an upper surface of the first hinge arm 34. It should be understood that one or more of the compression member 140 and/or the compression member 140 a′ can be installed to the door bracket 32 and any of a variety of locations to contact one of the first hinge arm 34, the second hinge arm 36 or both the first and second hinge arms 34 and 36.

Sixth Embodiment

Referring now to FIG. 35, a hinge structure 120′ in accordance with a sixth embodiment will now be explained. In view of the similarity between the first and sixth embodiments, the parts of the sixth embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the seventh embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity. The parts of the sixth embodiment that differ from the parts of the first embodiment will be indicated with a single prime (′)

In the sixth embodiment, the hinge structure 120 according to the second embodiment is modified thereby defining the hinge structure 120′. Specifically, the hinge structure 120′ includes the compressible check structure 122 of the third embodiment. Specifically, the compressible member 140 is installed to the body bracket 130 for contact with the hinge arm 134 provides essentially the same effects and function of the compressible check structure 122 as described above with respect to the third embodiment.

Seventh Embodiment

Referring now to FIG. 36-42, a hinge structure 120″ in accordance with a seventh embodiment will now be explained. In view of the similarity between the first, second and seventh embodiments, the parts of the seventh embodiment that are identical to the parts of the first and second embodiments will be given the same reference numerals as the parts of the first or second embodiments. Moreover, the descriptions of the parts of the seventh embodiment that are identical to the parts of the first or second embodiments may be omitted for the sake of brevity. The parts of the seventh embodiment that differ from the parts of the first and second embodiments will be indicated with a single prime (′) or a double prime (″).

In the seventh embodiment, the hinge structure 120 of the second embodiment is modified thereby defining the hinge structure 120″. Specifically, the hinge structure 120 is modified by the removal of the check structure 22 and the hinge structure 120″ is provided with a hydraulic check structure 222. Further, the hinge structure 120″ is installed to the vehicle 10 and the door 12, supporting the door 12 during pivoting movement between the closed position and the open positions of the door 12.

The hinge structure 120″ includes the above described body bracket 130 and the hinge arm 134. The body bracket 130 includes a pivot pin P₆ as shown in FIG. 38. The hinge arm 134 is fixedly attached to the pivot pin P₆ such that both the hinge arm 134 and the pivot pin P₆ can rotate or pivot relative to the body bracket 130 about a pivot axis A₆. The hinge arm 134 is formed integrally with a door bracket portion 132 as a single, unitary, monolithic element. The body bracket 130 is configured to attach to the vehicle 10 and the door bracket portion 132 is configured to attach to the door 12 in a manner similar to the hinge structure 20 of the first embodiment. However, as discussed above, the hinge structure 20 of the first embodiment is configured to support the door 12 for pivoting movement along a 170 degree movement path. In the second and seventh embodiments, the hinge structure 120 is configured to support the door 12 for pivoting movement along a movement path that is less than 170 degrees, for example, 90 degrees.

The check structure 222 includes a case 250, a shaft 252, a top seal 254, a cap 256, a lower seal 258 and a base plate 260.

The case 250 is a cylindrically shaped member non-movably attached via the base plate 260 to the body bracket 130 such that the case 250 does not pivot or rotate relative to the body bracket 130. More specifically, the case 250 and/or the base plate 260 can be mechanically fastened to the body bracket 130 or can be welded or otherwise rigidly fixed to the body bracket 130 in a conventional manner. The case 250 has a cylindrically shaped inner surface 250 a that defines a fluid chamber within the case 250. The case 250 includes a wall portion 250 b that is rigidly fixed to the cylindrically shaped inner surface 250 a and extends radially inward to the pivot shaft 252. A radially inner edge 250 c of the wall portion 250 b can include a seal (not shown) or can be finely machined to contact the shaft 252 creating a fluid seal therebetween. Specifically, the shaft 252 rotates relative to the case 250 and the wall portion 250 b. However, hydraulic fluid within the case 250 is prevented from passing between the radially inner edge 250 c and the shaft 252.

The wall portion 250 b is a rectangular shaped structural element that is rigidly and non-movably attached to the inner surface 250 a of the case 250.

The shaft 252 includes a paddle 252 a having fluid apertures 252 b and a lower shaft portion 252 c. The paddle 252 a is rigidly fixed to the shaft 252 and pivots with the shaft 252. The fluid apertures 252 b extend from a first side 252 d to a second side 252 e of the paddle 252 a. The fluid apertures 252 b are dimensioned to limit flow of hydraulic fluid from one of the first and second sides 252 d and 252 e to the other of the first and second sides 252 d and 252 e as is explained in greater detail below. A radially outer most edge 252 g can include a seal (not shown) or can be finely machined to contact the cylindrically shaped inner surface 250 a of the case 250 creating a fluid seal therebetween.

The lower shaft portion 252 c is configured to pivot with the pivot pin P₆ and the hinge arm 134. For example, the lower shaft portion 252 c can be integrally formed with the pivot pin P₆ of the hinge structure 120″ as a single monolithic shaft or pin, or alternatively can be provided with interlocking surfaces that connect the two together such that lower shaft portion 252 c and the pivot pin P₆ are fixedly connected to one another. Further, the shaft 252 and the pivot pin P₆ are supported for pivoting movement relative to the case 250 and relative to the body bracket 130. Rather, the shaft 252 and the pivot pin P₆ are fixed to or otherwise mechanically fastened to the hinge arm 134 for pivoting movement therewith. The door bracket 132 being fixed to, for example, the door 12 pivots about the axis A₆ and causes corresponding movement of the paddle 252 a while the casing 250 remains stationary being non-movably fixed to the body bracket 130.

The cap 252 defines a shaft support structure that supports an upper end of the shaft 252 in a conventional manner. Specifically, the cap 252 can include a bushing or bearing (not shown) that supports the shaft 252 for pivoting movement with respect thereto.

The cap 256 and the base plate 260 are configured to rigidly and fixedly attach to the case 250 in a conventional manner, such as mechanical threads or other conventional mechanical attachment structure. The top seal 254 is interposed between the cap 256 and the upper end of the case 250 thereby sealing the upper end of the case 250. Similarly, the lower seal 258 is interposed between the base plate 260 and the lower end of the case 250 thereby sealing the lower end of the case 250.

The base plate 260 includes a shaft opening that defines a bushing and receives the lower shaft portion 252 c thereby defining another shaft support structure. The base plate 260 also includes a projection 260 a that is described in greater detail below. It should be understood from the drawings and the description herein that the case 250 can be constructed with the cap 256 as an integral part thereof, thereby eliminating the need for the top seal 254.

When fully assembled and installed to the body bracket 130 of the hinge structure 120″, the case 250 is sealed and filled with hydraulic fluid. The wall portion 250 b, as described above, is shaped and dimensioned relative to the fluid chamber defined by the case 250 is such that hydraulic fluid is prevented from moving from a first side of the wall portion 250 b to a second side of the wall portion 250 b. Consequently when there is pivoting movement of the shaft 252 within the case 250, the hydraulic fluid is forced to move through the fluid apertures 252 b from one of the first side 252 d and the second side 252 e of the paddle 252 a to the other of the first side 252 d and the second side 252 e of the paddle 252. Therefore, force is required to pivot the shaft 252 in order to overcome the resistance to fluid flow provided by the paddle 252. Since the shaft 252 is fixed to the pivot pin P₆, the pivot pin P₆ is fixed to the hinge arm 134 and the door bracket 132, and the door bracket 132 is fixed to the door 12, the check structure 222 provides resistance to movement of the door 12 from any and all movement positions. Hence, the check structure 222 is an infinite check structure in that it provides a constant resistance to movement regardless of the location of the door 12, whether open partially open or fully open.

The amount of resistance to movement of the door 12 via the check structure 222 depends is part upon the type of hydraulic fluid used within the case 250 and the number and overall dimensions of the fluid apertures 252 b. For a vehicle having a large heavy door mounted to the hinge structure 120″, a larger size and/or larger number fluid apertures 252 b are necessary. For a smaller door mounted to the hinge structure 120″, a smaller diameter and/or smaller number fluid apertures 252 b are necessary.

The projection 260 a of the base plate 260 is a stop flange that extends into the hydraulic chamber and defines a stop surface that contacts the paddle 252 a as shown in FIG. 40. Specifically, the projection 260 a limits pivotal movement of the pivot shaft 252 and the paddle 252 a due to contact between the paddle 252 a and the projection 260 a.

Since fluid is prevented from moving around the wall portion 250 b (from a first side of the wall portion 250 b to a second side of the wall portion 250 b) pivoting movement of the shaft 252 and the paddle 252 a forces the hydraulic fluid to move through the fluid apertures 252 b from one of the first and second sides 252 d and 252 e of the paddle 252 a to the other of the first and second sides 252 d and 252 e of the paddle 252 a.

When the paddle 252 a is in contact with the projection 260 a, as shown in FIG. 40, the shaft 252 is prevented from moving in the counter clockwise direction because the projection 260 a serves as a stop surface. Therefore, the projection 260 a defines a limiter restricting pivoting movement of the paddle 252 a, the shaft 252, and the door 12. With the door 12 installed to the hinge structure 120″, the position of the paddle 252 a in FIG. 40 corresponds to the door 12 being in a fully open position, as shown in FIG. 3.

In order to move the door 12 away from the fully open position, force must be applied to the door 12 (and the hinge structure 120″) in order to force the fluid on the second side 252 e of the paddle 252 a to move through the fluid apertures 252 b to the first side 252 d of the paddle 252 a. The fluid pressure built up on the second side 252 e of the paddle 252 a forces the hydraulic fluid within the case 250 to move through the fluid apertures 252 b. As the hydraulic fluid moves, the paddle 252 a, the hinge arm 134 and the door 12 will move away from the fully open position to, for example, the intermediate open position shown in FIG. 2 and corresponding to the position of the paddle 252 a shown in FIG. 41. Further movement of the door 12, the hinge structure 120″, the shaft 252 and the paddle 252 a continues to force hydraulic fluid through the fluid apertures 252 b until the door 12 closes, as shown in FIG. 1, and with the paddle 252 a moved to the position shown in FIG. 42.

Once the door 12 is moved to a desired position, with the shaft 252 and the paddle 252 a being stationary relative to the case 250, equilibrium of fluid pressure of the hydraulic fluid at the first side 252 d and the second side 252 e of the paddle 252 a imparts a resistance to pivoting movement of the shaft 252 (and the door 12) relative to the case 250, the body bracket 130 and the vehicle 10.

In FIG. 42, the wall portion 250 b serves as another stop surface that prevents further movement of the paddle 252 a and the shaft 252. Consequently positioning of the base plate 260 and the projection 260 a relative to the case 250 and the wall portion 250 b of the case 250 provides a means for adjusting the total angle of pivoting movement of check structure 222 relative to the hinge structure 120″. For example, in the depicted embodiment, and in particular FIGS. 40-41, the check structure 222 is adjusted to operate with a hinge structure that has an overall pivoting range of approximately 90 degrees. The relative positions of the projection 260 a and the wall portion 250 b can be changed by repositioning the base plate 260 relative to the case 250 for a hinge structure that has an overall pivoting range of approximately 170 degrees, or any pivoting range.

In the seventh embodiment, the check structure 222 is located at an upper side of the body bracket 130. However, in should be understood that the check structure 222 can be installed to any of a variety of locations and can be used with any of a variety of hinge structures. For example, the check structure 222 can be installed to the hinge structure 20 shown in FIGS. 3-19 replacing the optional primary check structure 38. Further the check structure 222 can be installed to the hinge structure 120 depicted in FIGS. 20 and 21.

In modification to the seventh embodiment, the stop projection 260 a can alternatively be formed with or fixed to a portion of the cylindrically shaped inner surface 250 a of the case 250. Such a stop projection on the cylindrically shaped inner surface 250 a of the case 250 has the same effect as the stop projection 260 a described above.

Eighth Embodiment

Referring now to FIG. 43, a hinge structure 220 in accordance with an eighth embodiment will now be explained. In view of the similarity between the first and eighth embodiments, the parts of the eighth embodiment that are identical to the parts of the first embodiment will be given the same reference numerals as the parts of the first embodiment. Moreover, the descriptions of the parts of the eighth embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity.

The hinge structure 220 includes a first bracket 230 and a hinge arm 234 that includes an integrally formed second bracket. One of the first bracket 230 and the second bracket is a door bracket and the other is a body bracket. The hinge arm 234 pivots relative to the first bracket 230. The check structure 222 (the hydraulic check structure of the seventh embodiment) is installed to the hinge structure 220 along an upper portion of the hinge arm 234. The case 250 of the check structure 222 is non-movably fixed to the hinge arm 234. The shaft 252 and paddle 252 a of the check structure 222 are fixed to the pivot pin (not shown) of the hinge structure 220 for pivoting movement with the first bracket 230. Operation of the check structure 222 is identical to that described above with respect to the seventh embodiment, except that the overall pivoting range of the check structure 222 is adjusted to the overall pivoting range of the hinge structure 220, which can be, for example, anywhere between 60 degrees up to 120 degrees or any angle therebetween.

Nine Embodiment

Referring now to FIG. 44, a hinge structure 220′ in accordance with an ninth embodiment will now be explained. In view of the similarity between the above described embodiments and ninth embodiments, the parts of the ninth embodiment that are identical to the parts of the above described embodiments will be given the same reference numerals as the parts of the above described embodiments. Moreover, the descriptions of the parts of the ninth embodiment that are identical to the parts of the above described embodiments may be omitted for the sake of brevity. The parts of the ninth embodiment that differ from the parts of the above described embodiments will be indicated with a single prime (′).

The hinge structure 220′ is identical to the hinge structure 220 of the eighth embodiment except that the location of the check structure 222 has changed. The hinge structure 220′ includes the first bracket 230 and the hinge arm 234 of the eighth embodiment. However, the check structure 222′ (the hydraulic check structure) is installed to the hinge structure 220′ between upper and lower plates of the first bracket 230. The case 250′ of the check structure 222′ is non-movably fixed to one or both of the upper plate and the lower plate of the first bracket 230. The shaft 252 and paddle 252 a of the check structure 222 are fixed to the pivot pin (not shown) of the hinge structure 220′ for pivoting movement with the hinge arm 234. Operation of the check structure 222′ is identical to that described above.

The various vehicle parts and structural elements are conventional components that are well known in the art. Since vehicle parts and elements are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

General Interpretation Of Terms

In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiments, the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and “transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the vehicle door check structure. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the vehicle door check structure.

The term “configured” as used herein to describe a component, section or part of a device includes mechanical features constructed to carry out the desired function.

The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such features. Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 

What is claimed is:
 1. A vehicle door hinge structure comprising: a first bracket having a first surface that extends in a first direction and a stop surface extending in a second direction transverse to the first direction; a hinge arm having a first end, a second end and a body portion extending from the first end to the second end, the first end being attached to the first bracket for pivoting movement about a first pivot axis that extends through the first surface of the first bracket such that the hinge arm pivots relative to the first bracket from a first position to a second position, the body portion of the hinge arm having a movement limiting surface that is spaced apart from the first surface by a first predetermined distance; a second bracket attached to the second end of the hinge arm for pivoting movement about a second pivot axis that extends through the second bracket and the second end of the hinge arm, the second bracket pivoting relative to the second end of the hinge arm; and a compressible check structure fixed in position along a portion of the first surface of the first bracket, the compressible check structure being adjacent to and spaced apart from the stop surface of the first bracket, the compressible check structure extending away from the first surface in an uncompressed state by a second predetermined distance that is greater than the first predetermined distance, the movement limiting surface of the hinge arm contacting and compressing the compressible check structure during a portion of movement of the hinge arm between the first position and the second position.
 2. The vehicle door hinge structure according to claim 1, wherein the compressible check structure is made of an elastic material such that contact between the compressible check structure and the movement limiting surface of the hinge arm during movement of the hinge arm between the first position and the second position generates friction therebetween.
 3. The vehicle door hinge structure according to claim 1, wherein the compressible check structure is spaced apart from the stop surface of the first bracket such that a gap is defined between the stop surface and the compressible check structure, and with the movement limiting surface of the hinge arm being disposed within the gap, the hinge arm is in the second position.
 4. The vehicle door hinge structure according to claim 3, wherein the gap has a first overall length measured from the edge of the compressible check structure to the stop surface, and the movement limiting surface of the hinge arm has a first width measured in a widthwise direction of the hinge arm, the first overall length and the first width being approximately equal.
 5. The vehicle door hinge structure according to claim 1, wherein the first surface of the first bracket defines an aperture that extends from the first surface to a second surface of the first bracket opposite the first surface, and the compressible check structure includes a main body, a compressible portion located at a first end of the main body, and a retention portion located at a second end of the main body, the main body of the compressible check structure extending through the aperture of the first bracket, the compressible portion being located along the first surface of the first bracket surrounding the aperture and the retention portion facing the second side of the first bracket.
 6. The vehicle door hinge structure according to claim 5, wherein the main body of the compressible check structure has a rectangular cross-section, and the aperture of the first bracket has a corresponding rectangular shape, the main body and the aperture being dimensioned to prevent rotation of the compressible check structure with the main body inserted into the aperture.
 7. The vehicle door hinge structure according to claim 6, wherein the main body of the compressible check structure has a first side surface and a second side surface substantially parallel to one another, a third side surface and a fourth side surface substantially parallel to one another and perpendicular to the first and the second side surfaces, and the retention portion of the compressible check structure includes a first compressible flange and a second compressible flange, the first and the second compressible flanges extending from the second end of the main body of the compressible check structure toward the first end of the main body, with respective distal ends of the first and the second compressible flanges facing the second side of the first bracket with the main body inserted into the aperture preventing the retention portion from passing through the aperture from the second side of the first bracket to the first side of the first bracket.
 8. The vehicle door hinge structure according to claim 7, wherein the first compressible flange extends adjacent to the first side surface of the main body and the second compressible flange extends adjacent to the second side surface, a lengthwise extending surface of the first compressible flange and the first side surface of the main body defining an acute angle therebetween and a lengthwise extending surface of the second compressible flange and the second side surface of the main body defining an acute angle therebetween.
 9. The vehicle door hinge structure according to claim 5, wherein the compressible portion has a base that is wider than a width of the aperture and is located adjacent the first side of the first bracket with the main body inserted into the aperture.
 10. The vehicle door hinge structure according to claim 1, wherein at least a portion of a first side of the hinge arm faces the stop surface of the first bracket.
 11. The vehicle door hinge structure according to claim 1, wherein the hinge arm comprises a first gooseneck member and a second gooseneck member, the first gooseneck member defining the first end and the second end of the hinge arm, the second gooseneck member having a first end and a second end, the first end being attached to the first bracket for pivotal movement about a third pivot axis that extends through the first surface of the first bracket such that the second gooseneck member pivots about the third pivot axis relative to the first bracket from a first position to a second position, and the second bracket is attached to the second end of the second gooseneck member for pivotal movement about a fourth pivot axis that extends through the second bracket, the second bracket pivoting about the fourth pivot axis relative to the second end of the second gooseneck member, the first pivot axis and the third pivot axis being spaced apart from one another and parallel to one another, and the second pivot axis and the fourth pivot axis being spaced apart from one another and parallel to one another.
 12. The vehicle door hinge structure according to claim 1, wherein the first bracket is a body bracket configured to attach to a vehicle body structure and the second bracket is a door bracket configured to attach to a vehicle door.
 13. A vehicle comprising: a body structure defining a door opening; a door bracket rigidly attached to the body structure and having a first surface that extends in a first direction and a stop surface extending in a second direction transverse to the first direction; a hinge arm having a first end, a second end and a body portion extending from the first end to the second end, the first end being attached to the first bracket for pivoting movement about a first pivot axis that extends through the first surface of the door bracket such that the hinge arm pivots relative to the door bracket from a first position to a second position, the body portion of the hinge arm having a movement limiting surface that is spaced apart from the first surface by a first predetermined distance; a door attached to the second end of the hinge arm for pivoting movement about a second pivot axis that extends through the door and the second end of the hinge arm, the door pivoting relative to the second end of the hinge arm from a closed position covering the door opening to an open position exposing the door opening; and a compressible check structure fixed in position along a portion of the first surface of the door bracket, the compressible check structure being adjacent to and spaced apart from the stop surface of the door bracket, the compressible check structure extending away from the first surface in an uncompressed state by a second predetermined distance that is greater than the first predetermined distance, the movement limiting surface of the hinge arm contacting and compressing the compressible check structure during a portion of movement of the hinge arm between the first position and the second position.
 14. The vehicle door hinge structure according to claim 13, wherein the compressible check structure is made of an elastic material such that contact between the compressible check structure and the movement limiting surface of the hinge arm during movement of the hinge arm between the first position and the second position generates friction therebetween.
 15. The vehicle door hinge structure according to claim 13, wherein the compressible check structure is spaced apart from the stop surface of the door bracket such that a gap is defined between the stop surface and the compressible check structure, and with the movement limiting surface of the hinge arm being disposed within the gap, the hinge arm is in the second position.
 16. The vehicle door hinge structure according to claim 15, wherein the gap has a first overall length measured from the edge of the compressible check structure to the stop surface, and the movement limiting surface of the hinge arm has a first width measured in a widthwise direction of the hinge arm, the first overall length and the first width being approximately equal.
 17. The vehicle door hinge structure according to claim 14, wherein the first surface of the door bracket defines a aperture that extends from the first surface to a second surface of the door bracket opposite the first surface, and the compressible check structure includes a main body, a compressible portion located at a first end of the main body, and a retention portion located at a second end of the main body, the main body extending through the aperture of the door bracket, the compressible portion being located along the first surface of the door bracket surrounding the aperture and the retention portion being positioned on the second side of the hinge arm.
 18. The vehicle door hinge structure according to claim 17, wherein the main body of the compressible check structure has a rectangular cross-section, and the aperture of the door bracket has a corresponding rectangular shape, the main body and the aperture being dimensioned to prevent rotation of the compressible check structure with the main body inserted into the aperture, and the retention portion includes a plurality of snap-fitting flanges that engage the second surface of the door bracket with the main body inserted into the aperture.
 19. The vehicle door hinge structure according to claim 13, wherein the hinge arm comprises a first gooseneck member and a second gooseneck member, the first gooseneck member defining the first end and the second end of the hinge arm, the second gooseneck member having a first end and a second end, the first end being attached to the door bracket for pivotal movement about a third pivot axis that extends through the first surface of the door bracket such that the second gooseneck member pivots about the third pivot axis relative to the door bracket from a first position to a second position, and the door is attached to the second end of the second gooseneck member for pivotal movement about a fourth pivot axis, the door pivoting about the fourth axis relative to the second end of the second gooseneck member from the closed position to the open position.
 20. The vehicle door hinge structure according to claim 13, wherein the first pivot axis and the third axis are spaced apart from one another and are parallel to one another, and the second pivot axis and the fourth pivot axis are spaced apart from one another and are parallel to one another. 